Method and facility for enveloping an item to be packaged

ABSTRACT

A method for enveloping an item to be packaged includes supplying the item to a wrapping unit using a first feed unit, cutting a packaging blank having two side flaps, a base flap, and a closing flap to size, supplying the packaging blank to the wrapping unit using a second feed unit, combining the item and the packaging blank in the wrapping unit, and wrapping the item with the packaging blank, wherein the item and the packaging blank are supplied to the wrapping unit in a line and in opposite directions, at least in one section. This method further includes wrapping the item by folding the side flaps, and by folding the base flap, in any order, gluing the side flaps and the base flap together, and wrapping the item by folding the closing flap.

The invention relates to a process for enveloping of the item to bepackaged with the method steps of (a) supplying the item to be packagedto a wrapping unit by way of a first feed unit, (b) cutting a packagingblank to size from a provided material, (c) supplying the packagingblank to the wrapping unit by way of a second feed unit, (d) combiningthe item to be packaged and the packaging blank in the wrapping unit,and (e) wrapping the item to be packaged with the packaging blank by wayof the wrapping unit, wherein the item to be packaged and the packagingblank are supplied to the wrapping unit in at least one section in aline and in mutually opposite directions. Furthermore, the inventionrelates to a facility for enveloping an item to be packaged, with areceiving unit and a cutting unit for producing packaging blanks from aprovided material, a wrapping unit, a first feed unit for supplying theitem to be packaged to the wrapping unit and a second feed unit forsupplying the packaging blanks to the wrapping unit, wherein the firstand the second feed unit are arranged such that supplying the item andthe packaging blanks occurs in at least one section in a line and inmutually opposite directions.

Both the item to be packaged and the packaging pass through manydifferent stations from the production of the item, in particularmagazines, (advertising) brochures or letters and packages to thefinished, packaged item. The production of the item and the productionof the package are spatially separated from each other and combinedmanually or automatically by an enveloping facility only during theenveloping process. However, such decentralized production of theindividual packaging components leads to additional production costs,among other things, due to transport and storage costs, and longerproduction times, among other things, due to the transport routes, orloss of production when the item or the packaging material is not instock and must be ordered externally.

Newer enveloping facilities therefore attempt to take over individualproduction steps in the production of the item or the packaging and thusto reduce the production time and production costs. The production ofthe item, in particular printing, cutting and sorting of the blanks istypically handled by an internal production unit and the item is passeddirectly to the enveloping facility. This item is then automaticallyplaced by the enveloping facility in the provided packaging. This typeof enveloping facility has the disadvantage that the packaging must beproduced externally, resulting in additional transportation and storagecosts.

In other enveloping facilities both the production of the item as wellas the production of the package is assumed by the enveloping facility.In this case, a web of material is printed by an external printing unitsuch that initially the entire item is printed on the web of material,for example, individual sheets of a letter, before a packaging blank,for example an envelope with an address field, is printed onto the webof material. This completed web with multiple alternating items andpackaging blanks is then added to the enveloping facility, which cutsthe web of material in accordance with the items and the packagingblanks and then combines both of them. However, this method has thedisadvantage that due to the common web of material the items andpackaging blanks are always made of the same material. Such a limitationof the materials is in many cases undesirable.

It is therefore the object of the invention to provide a method forenveloping an item to be packaged and a corresponding facility, whichallow a particularly flexible, easy and quick packaging of the itemwhile keeping the production costs and production times low.

Regarding the method, this object is attained with the invention in thatthe packaging blank includes two side flaps, a bottom flap and a closureflap, and in that the wrapping of the item to be packaged includes theadditional method steps: wrapping the item to be packaged by folding theside flaps, and wrapping the item to be packaged by folding the bottomflap, in any order, adhesively joining the side flaps and the bottomflap, wrapping the item to be packaged by folding the closure flap. Withrespect to facility, this object is attained in that the packaging blankincludes two side flaps, a bottom flap and a closure flap and thewrapping unit includes means for folding the side flaps and the bottomflap, means for adhesively joining the side flap and the bottom flap,and means for wrapping the item to be packaged by folding the closureflap.

Advantageous embodiments of the invention are subject of the dependentclaims.

The invention proceeds from the consideration that the production costsand production times are significantly influenced by the use of externalproduction facilities and resulting delivery times and required storagespace. A reduction of these costs and production times can therefore beachieved when both the item to be packaged and the packaging can bemanufactured on site. A further reduction is possible, when also thestorage of the items or packages produced on site can be avoided and theproduction and enveloping can take place within a single facility. For amost flexible and customizable enveloping, the packages are not producedbefore being combined with the item to be packaged, but rather onlypackaging blanks are provided. To avoid further process steps and supplyof the packaging blanks over several feed conveyors, packaging blanksare made in one piece and already complete. This means that they alreadyinclude the side flaps, the bottom flap and the cover flap, and thepackaging blank need not be made or completed only in a further step,before or after the material is supplied, for example in the form of awrapper. These packaging blanks are combined with the item and the itemis only thereafter wrapped by folding the packaging blank. Changes inthe feed direction should therefore always be avoided to facilitate easycombination and accurate positioning of the item and the packagingblanks. For this reason, the item and the packaging blanks are suppliedfrom a bird's-eye-view in a line and in mutually opposite directions.This opposing arrangement makes the two feed units and the upstreamunits that supply and/or produce the packaging blank and the itemparticularly easily accessible.

For providing a most stable and secure package, the side edges arefolded first, then the bottom cover, and only thereafter the closureflap. Such a sequential order of folding and gluing enables theproduction of standard (letter) envelopes that meet the particularlystringent requirements for stability of the packaging. With this foldingsequence, the maximum space for the item to be packaged can be providedfor predetermined package sizes, for example by guidelines from theletter or parcel delivery service. In an alternative embodiment, thebottom flap may be folded first, followed by folding the side edges andthe closure flap. In this type of folding, the side edges and the bottomflap are adhesively joined outside. A possible contact between theadhesive material and the material can thus be prevented.

In a particularly advantageous embodiment, the item to be packaged andthe packaging blanks are combined in line and in the same direction forfast and secure enveloping of the item. This allows the item to bereadily and accurately positioned on the packaging blanks and combined,without relative movement of the item and the packaging blank. This alsoenables a continuous operation of the facility with a constant supply ofpackaging blanks without necessitating short downtimes or a stop-and-goapproach.

For a particularly precise folding of the packaging blank, folding inthe direction of movement of the packaging blank is consistentlyavoided. The side edges are folded parallel to the direction of movementand the packaging blank is positioned underneath the item so that thebottom flap can be folded against the direction of movement. In aparticularly preferred embodiment, to prevent the closure flap fromfolding in the direction of movement of the packaging blank, thedirection of movement of the already partially wrapped item is rotatedby about 90°, without rotating the packaging blank. Folding of theclosure flap parallel to the direction of movement is made possible onlyby this rotation. This particular guiding of the packaging blank duringfolding enables the production of packages and, in particular envelopes,wherein the folded edge of the closure flap and the folded edge of thebottom flap are arranged substantially parallel to one another. Sizerequirements, for example stipulated by a letter or parcel deliveryentity, can then be readily satisfied. However, other forms of packagingmay also be prepared depending on customer specifications by suitablyselecting the change in angle of the direction of movement.

In a preferred embodiment for applications having substantial variety,in particular for the production of packages and envelopes with windowelements, a window element is cut into the packaging blank while orafter the packaging blank is cut to size. This window element is thencovered by a window foil. The window foil is glued to the inside of thepackaging blank and completely covers the window element.

In the present facility, the packaging blanks are cut directly from aweb of material. This means that any addresses, advertising fields orcompany logos can already be printed on the packages on the web ofmaterial. However, this has the disadvantage that some changes or errorscan result in the replacement of the entire web of material. In anadvantageous embodiment, to provide printed envelopes particularlyflexibly and cost-effectively, the cut-to size packaging blanks areprinted rather than the web of material. A single, non-printed web ofmaterial can then be used for producing the packaging. With thisapproach, storage of printed webs of materials or waste of whole webs ofmaterial due to misprints or order changes can thus be avoided. In analternative or additional advantageous embodiment, printing of thepackaging after the item is wrapped is also contemplated.

In a preferred embodiment, to reduce the storage costs and the requiredstorage volume, the item, which is usually a letter, a flyer or abrochure, may also be cut from a web of material, with the cut-to sizepieces supplied directly to the wrapping unit. As with envelopes, it ishere also conceivable to cut the item from a non-printed web of materialand to only print individually with a printing unit after cutting. In aparticularly preferred embodiment, for combining the item to be packagedand the packaging blank with particular positional accuracy, the itemsto be packaged together are collected, after being cut to size, by acollecting unit and supplied together to the wrapping unit. It isconceivable that the collecting unit also performs a desired folding,gluing or other types of joining of the collected item.

The advantages attained with the invention are, in particular, that as aresult of a special supply of the item and the already completedpackaging blank, both can be particularly easily combined in thewrapping unit. Consequently, external production facilities can beconsistently eliminated both in the production of the item and in theproduction of the packaging, so that the item can be packaged at lowcost and with short downtimes. In addition, the materials used for theitems and the packaging can determined freely and independent from eachother and the dimensions of the cut pieces can be individually adjusted.

An exemplary embodiment of the invention will now be described in moredetail with reference to a drawing, which shows in:

FIG. 1 a schematic diagram of the method for enveloping an item to bepackaged,

FIG. 2 a schematic diagram of an enveloping facility.

Identical parts have in all figures identical reference symbols.

The schematic diagram of the method of FIG. 1 includes a first web ofmaterial 1 for the packaging blanks. The material of the web 1 can bechosen arbitrarily and according to the customer specifications; usuallypaper is used in different strengths, as well as a packaging foil. In afirst process step 2, the web of material 1 is cut by way of a cuttingunit 4 to produce packaging blanks 6. The cuts can be made to size forcreating a special individual design, which can also be changed from onepackaging blank 6 to another packaging blank 6 by a correspondingcontrol of the cutting unit. This enables a direct and optimumadaptation to the item 8 to be packaged. When the web of material 1 andhence also the packaging blanks 6 are already be completely printed, thepackaging blank 6 is supplied in the next process step 10 to thewrapping unit 12. Otherwise, the packaging blank 6 can be printedindividually and separately in an unillustrated process step by aprinting unit 14 before being supplied to the wrapping unit 12. Inaddition or alternatively, the web of material 1 may have already beenprinted by another printing unit 62. This has the advantage thatprinting can occur over the entire subsequent cut-to-size piece, thuseliminating system-induced non-printed edges. The package can be printedon both sides, i.e. outside and inside, by using two sequentiallyarranged printing units.

Furthermore, in another process step prior to feeding to the wrappingunit or in conjunction with cutting the packaging blank 6, a windowelement 68 is cut into the packaging blank 6 and later closed with awindow foil. In this way, packages with a window, in particularenvelopes, can be produced.

The schematic diagram of the method of FIG. 1 furthermore includes asecond web of material 16 for the manufacture of the item 8 to bepackaged This second web of material 16 is cut 22 with a second cuttingunit 18 into individual parts of the item 20. When the second web ofmaterial 16 is not yet printed, the individual parts of the item 20 canin a further process step be printed individually in an (unillustrated)additional printing unit. The parts of the item 20 are then supplied 26to a collection unit 24. This collection unit 24 is able to sort theparts of the item 20 and merge them into a single item 8. In addition,by using the collection unit 24, the item 8 can be folded, glued,embossed, connected with a staple or paperclip, or otherwise processedaccording to customer specifications. Furthermore, external enclosures64, such as, credit cards, CDs or promotional items, can be manually orautomatically added 66 to the item 8 by using the collection unit 24.The finished item 8 is thereafter fed 28 to the wrapping unit 12.

For particularly reliable and precise positioning of the item 8 on theassociated packaging blank 6 and an error-free further processing by thewrapping unit 12, the supply paths 10, 28 are arranged in a line, but inopposite directions. This makes rotating the item 8 in the plane ofmovement or the packaging blank during conveyance unnecessary, as wellas an undesirable displacement of the packaging blank 6 through changesin the feed direction. However, the material 8 and the packaging blank 6are joined in a line and in the same direction. This avoids relativemovements between the two and the item 8 can be placed with excellentpositional accuracy in a particularly simple manner, for example bysetting the item down on the packaging blank 6. With this particulartype of feeding, the item 8 to be packaged in the wrapping unit 12 islocated on the inside of the packaging blank 6.

In a first wrapping operation 30, the side flaps 32 of the packagingblank 6 are folded parallel to the direction of movement of thepackaging blank 6 and wrapped around the item 8. Simultaneously or in asubsequent process step, the outside of the side flaps is coated with anadhesive film. In a second wrapping operation 34, the bottom flap 36 isthen folded against the direction of movement of the packaging blank 6,wrapped around the item 8 and glued to the side flaps 32.

To prevent a fold in the direction of movement, the direction ofmovement of the packaging blank 6 and the item 8 inside is rotated byapproximately 90°, however, without changing the orientation of thepackaging blank 8. With this change of the direction of movementrelative to the orientation of the packaging blank 8, the closure flap40 can be folded 38 parallel to the new direction of movement of thepackaging blank 8. With this type of rotation of the direction ofmovement, the folding edges of the closure flap 40 and of the bottomflap 36 are arranged approximately parallel to each other, so thatparticularly symmetric packages can be produced. During this folding 38,the package is closed and the item 8 completely packaged. Depending onthe further processing of the packaged item 42, the closure flap 40 canbe glued directly to the end of the bottom flap 36 during folding. Tothis end, in another earlier process step or in a process step performedduring folding, an adhesive film can be applied directly in the endregion of the bottom flap 36 and/or on the inside of the closure flap40.

An exemplary embodiment of the enveloping facility 43 is schematicallyshown in FIG. 2. The enveloping facility 43 includes a packaging unit 44for producing and supplying the packaging blanks 6 to a wrapping unit 12and an item unit 46 for manufacturing, sorting, collecting and feedingthe item 8 also to this wrapping unit 12.

The packaging unit 44 includes—in the order of process steps—a receivingunit 48 for the packaging material, such as a web or reel of material 1,a cutting unit 4 which cuts this packaging material into packagingblanks 6, a first and a second printing unit 14, 62 which prints thepackaging blanks 6 as needed, and a feed unit 50 for supplying thepackaging blanks 6 to the wrapping unit 12. In addition, the packagingunit may include a unit for cutting and applying window elements 68 tothe packaging blank.

The item unit 46 also includes a separate receiving unit 52 for a web orreel of material 16. Parts of the item 20 are cut from the web ofmaterial 16 in a downstream, second cutting unit 18. These parts canoptionally be individually printed by another unillustrated printingunit. A collection unit 24 is arranged downstream of the cutting unit18, where the parts of the item 20 can be collected, sorted and furtherprocessed. Additional enclosures or other parts of the item 8 to bepackaged can be supplied externally either manually or automatically.The collected item 8 to be packaged is transferred to the wrapping unit12 via a dedicated feed unit 54.

The enclosure unit 12 is configured to safely and permanently enclosethe item 8 to be packaged with the supplied packaging blank 6 inmultiple folding and gluing steps. For the simplest and most accuratefolding of the closure flap, the wrapping unit 12 is L-shaped, whereinthe side flap and the bottom flaps are folded in a first partial area 56and the closure flap is folded in a second partial area 58, whereby thefirst partial area 56 is rotated by about 90°. The wrapping unitaccording to the exemplary embodiment of FIG. 2 moreover includes adedicated printing unit 60, where the finished end product 42 can beprinted again or for the first time, as needed.

The feed units 50, 54 of the packaging blank 6 and of the item 8 arearranged such that they are supplied—in a bird's eye view—in a line andin opposite directions. The packaging blank 6 is hereby brought intoproximity of the wrapping unit 12 at a lower level, i.e. below thewrapping unit 12, whereas the item 8 is supplied to the wrapping unit ata higher level above. When the packaging blank 6 is fed to the wrappingunit 12, the packaging blank 6 is moved along a segment of an arc or ofa circle. This corresponds to a roller-type rotation of the packagingblank 6 which, however, need not be realized with a roller element, butcan also be accomplished with a suitable arrangement of conveyor beltsor similar transport elements. With this type of rotation of thepackaging blank 6, its orientation relative to the direction of movementdoes not change, thus preventing a shift during the movement and hence alater inaccurate positioning.

With such conveyance of the item 8 and of the packaging blank 6, theitem can be accurately positioned on the packaging blank 6. Only thencan the item 8 be completely wrapped. Prefabricated and externallyproduced packages can thus be dispensed with.

LIST OF REFERENCE SYMBOLS

-   1 first web of material-   2 process step: cutting the first web of material-   4 cutting unit-   6 packaging blank-   8 good, item-   10 process step: feeding to the wrapping unit-   12 wrapping unit-   14 printing unit-   16 second web of material-   18 cutting unit-   20 parts of the item-   22 process step: cutting the second web of material-   24 collection unit-   26 process step: feeding to the collecting unit-   28 process step: feeding to wrapping unit-   30 process step: folding the side flaps-   32 side flaps-   34 process step: folding the bottom flap-   36 bottom flap-   38 process step: folding the closure flap-   40 closure flap-   42 final item-   43 enveloping facility-   44 packaging unit-   46 item unit-   48 receiving unit of the packaging unit-   50 feed unit of the packaging unit-   52 receiving unit of the item unit-   54 feed unit of the item unit-   56 partial area of the wrapping unit-   58 partial area of the wrapping unit-   60 printing unit-   62 printing unit-   64 external supplements-   66 process step: feeding of the external supplements-   68 window element

What is claimed is: 1-12. (canceled)
 13. A method of enveloping an itemto be packaged, comprising: supplying the item to be packaged to awrapping unit by way of a first feed unit, cutting a packaging blankmade of a provided material to size, said packaging blank having twoside flaps, a bottom flap and a closure flap, supplying the packagingblank to the wrapping unit by way of a second feed unit in at least onesection in a line, and in mutually opposite directions, combining theitem to be packaged and the packaging blank in the wrapping unit,wrapping the item to be packaged with the packaging blank by way of thewrapping unit, wherein wrapping the item to be packaged furthercomprises: wrapping the item to be packaged by folding of the side flapsand by folding of the bottom flap, in any order, adhesively joining theside flaps and the bottom flap, and wrapping the item to be packaged byfolding of the closure flap.
 14. The method of claim 13, wherein theitem to be packaged and the packaging blank are combined in the wrappingunit in a line and in mutually opposite directions.
 15. The method ofclaim 13, further comprising rotating a direction of movement of theitem, when the closure flap is folded and adhesively joined, bysubstantially 90° in relation to a direction of movement of the item,when the side flaps and the bottom flap are folded and adhesivelyjoined.
 16. The method of claim 13, wherein cutting the packaging blankto size further comprises: cutting a window element in the packagingblank, and covering the window element with a window foil.
 17. Themethod of claim 13, further comprising printing the packaging blankbefore supplying the packaging blank to the wrapping unit.
 18. Themethod of claim 13, further comprising printing the packaging blankafter wrapping the item in the wrapping unit.
 19. The method of claim13, wherein the item to be packaged supplied to the wrapping unit is cutfrom a second web of material.
 20. The method of claim 19, furthercomprising collecting a plurality of packaging blanks from the secondweb of material for the item to be packaged before supplying the item tothe wrapping unit.
 21. A facility for enveloping an item to be packaged,comprising: a receiving unit and a cutting unit for producing from aprovided material packaging blanks comprising two side flaps, a bottomflap and a closure flap, a wrapping unit comprising means for foldingthe side flaps and the bottom flap, means for adhesively joining theside flaps and the bottom flap, and means for wrapping the item to bepackaged by folding of the closure flap, a first feed unit for supplyingthe item to be packaged to the wrapping unit, and a second feed unit forsupplying the packaging blanks to the wrapping unit, wherein the firstand second feed unit are arranged so as to supply the item to bepackaged and the packaging blanks in at least one section in a line andin opposite directions.
 22. The facility of claim 21, further comprisingat least one printing unit.
 23. The facility of claim 21, furthercomprising a second web of material and a second cutting unit forproducing the item to be packaged.
 24. The facility of claim 23, furthercomprising a collection unit.